Orthogonal Battery Pack Cells for Universal Tool Compatibility
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Solution Overview
Problem
Existing battery packs for hand-held power equipment are often designed for specific tools, resulting in inefficiencies due to varying sizes and weights, which affect stability and production processes, and are prone to dust and debris interference with electrical contacts.
Innovation Solution
A battery pack configuration with cells arranged in orthogonal columns and rows, allowing for consistent dimensions and adjustable cell count to fit various tools, with a housing design that minimizes crevices to prevent dust and debris interference, ensuring balanced weight distribution and streamlined production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery packs are designed with specific sizes and weights for different tools, then each tool can be optimized for its specific needs, but production efficiency decreases and manufacturing complexity increases
Solution Approach 1:
The battery pack is designed with a standardized housing configuration that can accommodate different numbers of cells (e.g., 5, 10, 15, 20 cells) while maintaining the same external dimensions and profile. This universal design allows a single battery pack model to be used across multiple different power tools, eliminating the need for tool-specific battery designs and simplifying production lines while maintaining adaptability.
2Power
If battery pack size is increased to provide more power, then power output improves, but the aperture size required for insertion increases
Solution Approach 1:
Instead of increasing battery pack power by expanding in multiple dimensions (length, width, height), the design increases power output by adding more cells in a standardized grid pattern within the fixed housing. The power scaling is achieved through cellular multiplication rather than dimensional expansion, allowing the battery to fit through the same aperture while providing increased power capacity.
3Ease of manufacture
If traditional battery pack designs are used, then manufacturing is straightforward, but dust and debris can interfere with electrical contacts
Solution Approach 1:
The battery pack incorporates a sealed housing design that encloses the cells and electrical contacts, preventing dust and debris from entering and interfering with electrical connections. The housing acts as a protective barrier while maintaining manufacturing simplicity through standard enclosure techniques.
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A battery pack (510) for powering hand-held power equipment (400) may include a plurality of cells (20) and a housing (520). The plurality of cells (20) may be arranged in a series of columns. The housing may include sidewalls (526, 528) that enclose the plurality of cells (20) on sides parallel to a direction of insertion of the battery pack (510) into an aperture in the hand-held power equipment (400). The plurality of cells (20) may also be arranged such that a longitudinal length of each of the cells is substantially orthogonal to a direction of insertion of the battery pack (510) into the aperture.